Automotive Manufacturing Documentation

When to Activate This Skill

"Write a work instruction for [process]"
"Create a business process for [operation]"
"Document manufacturing procedure"
"Build SOP for [automotive process]"
"Create APQP documentation"
"Write quality inspection procedure"
"Document assembly/machining/material handling process"

Core Document Types

1. Work Instructions (WI)

Purpose: Detailed step-by-step operator guidance Key Elements:

Clear title and document ID
Scope and applicability
Required materials, tools, equipment
Safety warnings and PPE requirements
Numbered sequential steps with visual aids
Quality checkpoints and acceptance criteria
References to specifications/standards

2. Standard Operating Procedures (SOP)

Purpose: Standardized process methodology Key Elements:

Purpose and scope
Responsibilities and authorities
Process flowchart
Detailed procedure steps
Forms and records
Related documents
Revision history

3. Business Process Documents

Purpose: High-level process definition and control Key Elements:

Process ownership
Inputs and outputs
Key performance indicators (KPIs)
Process flow diagram
Interaction with other processes
Risks and controls
Continuous improvement tracking

Standards Compliance

IATF 16949 Requirements

Process approach methodology
Risk-based thinking
Turtle diagrams for process definition
FMEA linkage
Control plan alignment
Layered process audits consideration

ISO 9001 Structure

Context of organization
Leadership and planning
Support and operation
Performance evaluation
Improvement focus

APQP/PPAP Integration

Process flow diagrams
PFMEA considerations
Control plans
Work instructions as PPAP deliverables
Measurement system analysis references

Writing Framework

Document Structure Template

1. HEADER
   - Document Title
   - Document Number
   - Revision/Date
   - Approvals (Prepared/Reviewed/Approved)

2. PURPOSE & SCOPE
   - Why this document exists
   - What processes/operations it covers
   - What it doesn't cover

3. RESPONSIBILITIES
   - Who performs the work
   - Who supervises
   - Who approves/validates

4. SAFETY & PPE
   - Hazards and risks
   - Required personal protective equipment
   - Emergency procedures

5. MATERIALS & EQUIPMENT
   - Parts/components list
   - Tools required
   - Equipment specifications
   - Gages and measuring devices

6. PROCEDURE/STEPS
   - Sequential numbered steps
   - Action-oriented language (verb-first)
   - Visual aids (photos, diagrams)
   - Quality checks embedded

7. QUALITY REQUIREMENTS
   - Specifications and tolerances
   - Inspection frequency
   - Acceptance/rejection criteria
   - Rework procedures

8. RECORDS & DOCUMENTATION
   - What gets recorded
   - Where records stored
   - Retention requirements

9. REFERENCES
   - Related documents
   - Engineering drawings
   - Specifications
   - Standards

10. REVISION HISTORY
    - Date, revision, changes made

Process Type Guidelines

Assembly Operations

Focus: Sequence, torque specs, orientation
Include: Part numbers, installation direction, fastener specifications
Visuals: Assembly diagrams, before/after photos, exploded views
Checks: Fit, alignment, function tests

Machining Operations

Focus: Setup, program, tooling, parameters
Include: Machine settings, feed/speed, tool specifications, fixtures
Visuals: Setup photos, tool paths, measurement points
Checks: Dimensional verification, surface finish, first-piece inspection

Quality/Inspection

Focus: What to inspect, how to measure, accept/reject criteria
Include: Gage R&R references, sampling plans, measurement methods
Visuals: Measurement locations, gage usage, defect examples
Checks: Calibration verification, data recording

Material Handling

Focus: Movement, storage, protection, traceability
Include: Handling methods, storage conditions, labeling, FIFO
Visuals: Packaging methods, storage layouts, label formats
Checks: Condition verification, count accuracy, traceability

Best Practices

Writing Style

Active voice: "Insert the bolt" not "The bolt is inserted"
Present tense: "Check the torque" not "The torque should be checked"
Imperative mood: Direct commands to operator
Concise: One action per step
Specific: Exact values, not ranges when possible

Visual Elements

Photos of actual parts/processes (preferred)
Diagrams for complex assemblies
Flowcharts for decision points
Callouts for critical features
Color coding for emphasis (warnings in red/yellow)

Quality Integration

Embed quality checks within process steps
Reference control plans
Link to FMEA high-priority items
Include mistake-proofing (poka-yoke) features
Document inspection frequency

Revision Control

Clear document numbering system
Revision history table
Change bars for modified sections
Effective date tracking
Training requirements for changes

Common Mistakes to Avoid

Assuming operator knowledge
Missing safety information
Vague quantities or specifications
No visual aids for complex operations
Incomplete tool/equipment lists
Missing quality acceptance criteria
No revision history
Passive voice or unclear instructions

Quick Reference: Document Selection

Need	Document Type	Complexity
Operator guidance	Work Instruction	Low-Medium
Department procedure	SOP	Medium
Process definition	Business Process	Medium-High
Quality procedure	Quality SOP	Medium
Inspection method	Inspection WI	Low-Medium

Output Format

When creating documents, structure output as:

# [DOCUMENT TITLE]
**Document Number**: [AUTO-XXX-####]
**Revision**: [X] | **Date**: [YYYY-MM-DD]
**Prepared**: _____ | **Reviewed**: _____ | **Approved**: _____

## 1. Purpose & Scope
[Content]

## 2. Responsibilities
[Content]

[Continue with standard sections...]

Supplementary Resources

For comprehensive methodologies and advanced topics: read ~/.claude/skills/AutomotiveManufacturing/CLAUDE.md

For document templates: ls ~/.claude/skills/AutomotiveManufacturing/templates/

Integration with Related Skills

A3CriticalThinking

When manufacturing issues arise, use A3 problem-solving methodology:

Quality defects → Root cause analysis (5 Whys, Fishbone)
Process failures → Structured countermeasure development
Decision making → Apply priority hierarchy (Safety → Customer → Cost)

Load A3 skill: read ~/.claude/skills/A3CriticalThinking/SKILL.md

SupplyChain

For supplier-related documentation and requirements:

Supplier quality requirements in work instructions
PPAP documentation for purchased components
Incoming inspection procedures

Load SupplyChain skill: read ~/.claude/skills/SupplyChain/SKILL.md

HoshinKanri

For strategic alignment of manufacturing objectives:

Cascade targets to shop floor metrics
Link work instructions to quality objectives
Bowling chart for manufacturing KPIs

Load HoshinKanri skill: read ~/.claude/skills/HoshinKanri/SKILL.md

Key Principles

Priority Hierarchy (from A3CriticalThinking):

1. SAFETY FIRST     → Never compromise for cost or delivery
2. CUSTOMER VALUE   → Quality that meets/exceeds requirements
3. SHAREHOLDER VALUE → Optimize after 1 & 2 are secured

Safety First: Always lead with safety considerations - this is non-negotiable
Clarity Over Brevity: Be clear, even if it takes more words
Visual Communication: A picture is worth 1000 words
Measurable Requirements: Specific, measurable acceptance criteria
Traceability: Link to higher-level documents and standards
Living Documents: Build in revision and improvement processes
Problem Solving: Use A3 methodology for issues and improvements

automotivemanufacturing